Computer enclosure air distribution system

ABSTRACT

A computer cabinet includes a top panel and at least one side panel connected to the top panel and a fan assembly. The fan assembly includes a fan and a fan housing. The fan housing has a top half and bottom half. The top half and the bottom half form an internal cavity. An air inlet is located within one of the top and bottom halves. The fan is located within the internal cavity and directs air from the air inlet towards an open end of the housing.

RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional PatentApplication 60/390,265, filed Jun. 20, 2002.

FIELD OF THE INVENTION

[0002] The present invention relates generally to computer enclosures,and more specifically to a computer enclosure air distribution systemwith a centrifugal fan enclosed in a plastic housing

BACKGROUND OF THE INVENTION

[0003] Data processing and telecommunications computer centers typicallyhave a number of locked enclosures in a room that contains a number ofcomputer servers. The servers are generally stacked and mountedvertically in standardized racks, i.e., server cabinets which aretypically about 19 inches wide. Many of these computer centers utilizeraised floor air conditioning systems that deliver cool air to thebottom of the server cabinets via holes or perforations in the floortiles underneath the cabinet.

[0004] Computer server designs are becoming more compact in size,specifically height, and provide more capability. Thus, more servers maybe fit into the same sized cabinet, thereby generating more heat insidethe cabinet.

[0005] Most server designs are cooled internally by employing, smallaxial fans which draw cool air in from the front of the server andexhaust warmer air out the back of the server. As stated above, thereduced height servers may be packed more densely within the cabinet.This may result in the temperature near the top of the enclosure beingmuch warmer than the air near the cool air provided at the floor of thecabinet. This increase in heat may reduce the performance and durabilityof the server components.

[0006] One approach to cooling servers in a server rack uses a radialfan located in a generally rectangular internal cavity of a housingmounted on rails. The fan housing is mounted horizontally over anaperture located, for example, in a floor of the enclosure. The fan islocated at one end of the housing in the internal cavity. The housingmay include an opening in the top of the surface housing at an oppositeend to permit air flow out of the housing.

[0007] However, the generally rectangular shape of the interior housingresults in an uneven air flow out of the fan housing, which again, mayresult in reduced performance and durability of the server components.

[0008] The present invention is aimed at one or more of the problemsidentified above.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0009] In one aspect of the present invention, a fan assembly for use ina computer cabinet is provided. The cabinet includes a top panel and atleast one side panel connected to the top panel. The top panel and theat least one side panel form the cabinet. The fan assembly includes afan and a fan housing. The fan housing includes a top half and a bottomhalf. The top half and the bottom half form an internal cavity and anair inlet. The fan is located within the internal cavity for directingair from the air inlet towards an open end of the fan housing. Theinternal cavity has a scroll portion and a volute portion. The voluteportion has a narrow portion connected to the scroll portion and expandstowards the open end of the housing.

[0010] In another aspect of the present invention, a fan assembly foruse in a computer cabinet is provided. The cabinet includes a top paneland at least one side panel connected to the top panel. The top paneland the at least one side panel form the cabinet. The fan assemblyincludes a fan and a fan housing. The fan housing includes a top halfand a bottom half. The top half and the bottom half form an internalcavity and an air inlet. The fan is located within the internal cavityfor directing air from the air inlet towards an open end of the fanhousing. A front nozzle is connected to the fan housing at the open endof the fan housing.

[0011] In still another aspect of the present invention, a computercabinet is provided. The cabinet includes a top panel and at least oneside panel connected to the top panel. The top panel and the at leastone side panel form the cabinet. The fan assembly includes a fan and afan housing. The fan housing includes a top half and a bottom half. Thetop half and the bottom half form an internal cavity and an air inlet.The fan is located within the internal cavity for directing air from theair inlet towards an open end of the fan housing. The internal cavityhas a scroll portion and a volute portion. The volute portion has anarrow portion connected to the scroll portion and expands towards theopen end of the housing.

[0012] In still one more aspect of the present invention, a computercabinet is provided. The cabinet includes a top panel and at least oneside panel connected to the top panel. The top panel and the at leastone side panel form the cabinet. The fan assembly includes a fan and afan housing. The fan housing includes a top half and a bottom half. Thetop half and the bottom half form an internal cavity and an air inlet.The fan is located within the internal cavity for directing air from theair inlet towards an open end of the fan housing. A front nozzle isconnected to the fan housing at the open end of the fan housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Other advantages of the present invention will be readilyappreciated as the same becomes better understood by reference to thefollowing detailed description when considered in connection with theaccompanying drawings wherein:

[0014]FIG. 1 is a diagrammatic illustration of a rack assembly for aplurality of computer servers;

[0015]FIG. 2 is an exploded view of a portion of the rack assembly ofFIG. 1;

[0016]FIG. 3 is a partial view of the rack assembly of FIG. 2 having afan assembly, according to an embodiment of the present invention;

[0017]FIG. 4 is a top down view of a top portion of the fan assembly ofFIG. 3;

[0018]FIG. 5 is a perspective view of the top portion of the fanassembly of FIG. 4;

[0019]FIG. 6 is a top down view of a bottom portion of the fan assemblyof FIG. 3;

[0020]FIG. 7 is a perspective view of the bottom portion of the fanassembly of FIG. 6;

[0021]FIG. 8 is a first side view of the fan assembly of FIG. 3;

[0022]FIG. 9 is a second side view of the fan assembly of FIG. 3;

[0023]FIG. 10 is a third side view of the fan assembly of FIG. 3;

[0024]FIG. 11 is a fourth side view of the fan assembly of FIG. 3; and,

[0025]FIG. 12 is a perspective interior view of the fan assembly of FIG.3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0026] With reference to the drawings, and in operation, the presentinvention provides a computer enclosure air distribution system for usein a computer cabinet 10. With particular reference to FIG. 1, oneexample of a computer cabinet 10 in which the present invention issuitably adapted to is a rack-type computer cabinet 10 designed to holda plurality of computer servers 12. The computer servers 12 are storedin the computer cabinet 10 mounted to a rack system (see below).

[0027] As shown in FIG. 1, the computer cabinet 10 includes a top panel14 and at least one side panel 18. In the illustrated embodiment, thecomputer cabinet 10 includes three side panels 18, only one of which isshown. Additionally, a front side panel may be included to compete theenclosure. The front side panel may include a hinged access panel, i.e.,a door, which allows the computer cabinet 10 to be opened and closed forthe insertion/removal/repair of the computer servers.

[0028] With reference to FIGS. 2 and 3, the computer cabinet 10 includesa frame 20 to which the panels 14, 18 are connected using suitablefasteners, such as screws, thumb-screws, rivets, clips, etc. . . . . Theframe 20 includes a bottom portion 22 and a top portion 24 which areconnected by a plurality of upright members 26. In the illustratedembodiment, the bottom portion 22 includes front and back members 22A,22B, and two side rails 22C, 22D and the top portion 24 includes frontand back members 24A, 24B and two side rails 24C, 22D. The frame 20includes first, second, third, and fourth upright members 26A, 26B, 26C,26D which are connected between corners of the top and bottom portions22, 24. In one embodiment, the computer cabinet 10 includes a bottompanel 16 coupled to the bottom portion 22 of the frame 20. In anotherembodiment the bottom panel 16 is formed by the floor 16 on which thecabinet 10 is located. In the latter embodiment, the cabinet may or maynot be fixed or otherwise secured to the floor 16.

[0029] With particular reference to FIG. 2, in the illustratedembodiment, the bottom panel 16 includes an aperture 32. The computercabinet 10 may further include at least one pair of rails 26. Thecomputer server 12 may be secured in the computer cabinet 10 to theupright members or vertical rails 26A, 26B, 26C, 26D by a plurality offasteners (not shown) or other suitable mechanism. Such systems are wellknown in the art and are therefore not further discussed.

[0030] With particular reference to FIG. 3, the computer enclosure airdistribution system includes a fan assembly 30 for circulating air intothe computer cabinet 10, at least sometimes through an aperture 32 inthe bottom panel or floor 16 and redirecting the flow of air. The fanassembly 30 includes a housing 38. A pair of fan rails 34, 36 arecoupled to the frame 20. The pair of fan rails 34, 36 are adapted toslidably receive the fan-assembly 30.

[0031] In the illustrated embodiment, each fan rail 34, 36 includes afront portion 34A, 36A and a back portion 34B, 36B. The front and backportions 34A, 36A, 34B, 36B are slidably engaged such that the overalllength of each fan rail 34, 36 is adjustable to accommodate computercabinets with different depth dimensions.

[0032] In the illustrated embodiment, each rail 34, 36 includes a flange(not shown) having at least one aperture. Each upright member 26A, 26B,26C, 26D also includes a plurality of apertures. The fan rails 34, 36may be secured to the frame 20 by a plurality of fasteners or othermechanism (not shown). For example a threaded fastener may be threadedthrough the at least one aperture in the flange and a correspondingaperture in an upright member 26A, 26B, 26C, 26D.

[0033] With reference to FIGS. 4-7, the fan assembly 30 includes a fanhousing 38. In the illustrated embodiment, the fan housing 38 includes atop half 40 and a bottom half 42. The top half 40 and the bottom half 42each include an outer flange 44, 46 around at least a portion of itsouter edge. The outer flanges 44, 46 may include a plurality ofapertures 48 for receiving fasteners 50, e.g., screws, rivets, or clips.The top half 40 and the bottom half 42 are held together by an adhesiveand/or the fasteners 50 to form the fan housing 38.

[0034] With reference to FIG. 12 in the illustrated embodiment, the fanassembly 30 includes a centrifugal fan 52 connected to the top half 40of the fan housing 38. In one embodiment the centrifugal fan 52 includesa plurality of backward inclined fan blades 53, although forwardinclined fan blades may also be used. The centrifugal fan 52 alsoincludes an electric motor for rotating the fan blades when electricalpower is applied. Suitable centrifugal fans 52 are well known in the artand are therefore not further discussed.

[0035] The fan assembly 30 forms an internal cavity 54 and an air inlet56 located on one of the top and bottom halves 40, 42 (shown as beinglocated in the bottom half 42). The fan 52 is located generally withinthe internal cavity 54 and directs air from the air inlet towards anopen end 58 of the fan housing 38. The internal cavity 54 includesscroll portion 60 and a volute portion 62. The volute portion 62includes a narrow portion 64 connected to the scroll portion 60 andexpands towards the open end 58 of the fan housing 38. In another aspectof the present invention, the fan 52 is provided with an on/off switch(not shown) which projects from an on/off switch cavity 59.

[0036] In one embodiment, the fan assembly 30 further includes a frontnozzle 66 which is connected to the housing 38 at the of the open end 58of the housing 38. The front nozzle 66 directs air flow out of the fanassembly 30 in a desired direction. In the illustrated embodiment, thefront nozzle 66 directs the air flow at an angle generally 90 degreesfrom the direction of air flow out of the open end 58. In oneembodiment, the front nozzle 66 may be removably coupled to the housing38 via a snap-fit. In another embodiment, the front nozzle 66 may beremovably coupled to the housing 38 using a fastener (not shown), suchas a threaded fastener. In one aspect of the present invention, the fanassembly 30 includes an air filter 68. In one embodiment, the air filter68 is located in the outlet side of the fan assembly 30, e.g., withinthe front nozzle 66. In another embodiment, the air filter 68 is locatedon the inlet side of the fan assembly 30.

[0037] The centrifugal fan 52 is powered via a junction box 70 which maybe integrally molded with the housing 38. Electrical power is suppliedto the junction box 70 by a power cord, which is connected at one end tothe junction box 70 and to a power supply, e.g., an 115 volt, 60 Hz,alternating current power supply (not shown), at the other end. Thepower cord may be detachable. Power is supplied to the electrical motorof the fan 52 via a fan power cord 72.

[0038] In the illustrated embodiment, the top half 40 of the housing 38includes a hollow rib 74 for receiving the fan power cord 72 (indicatedby a dashed line).

[0039] In another aspect of the present invention, the air distributionsystem may include one or more thermostats which are positioned atdesired locations within the computer cabinet 10. The thermostats sensea temperature at their locations. The system controls the fan, i.e.,turns the fan on and off to maintain a desired temperature.

[0040] In use, the illustrated embodiment of the present inventionprovides a fan assembly 30 for use in a computer cabinet 10 which drawscool air from the floor through the aperture 25 in the bottom panel orfloor 16 and directs the flow of air through the detachable front nozzle66 in an upward vertical direction between the front of the computerservers 12 and the front of the computer cabinet 10.

[0041] The design of the fan housing 38, i.e., the shape of the internalcavity 54, optimizes air flow from the fan assembly 30, ensures agenerally uniform air flow out of the open end 58 or the front nozzle66. Additionally, the internal cavity 54 reduces undesirable tonal noisecharacteristics and provides for installation in a compact space.

[0042] Obviously, many modifications and variations of the presentinvention are possible in light of the above teachings. The inventionmay be practiced otherwise than as specifically described within thescope of the appended claims.

What is claimed is:
 1. A fan assembly for use in a computer cabinet, thecabinet having a top panel and at least one side panel connected to thetop panel, the top panel and the at least one side panel forming thecabinet, comprising: a fan; and, a fan housing having a top half andbottom half, the top half and the bottom half forming an internalcavity, an air inlet being located on one of the top and bottom halves,the fan being located within the internal cavity for directing air fromthe air inlet towards an open end of the fan housing, the internalcavity have a scroll portion and a volute portion, the volute portionhaving a narrow portion being connected to the scroll portion andexpanding towards the open end of the housing.
 2. A fan assembly, as setforth in claim 1, further comprising a front nozzle connected to thehousing at the open end of the housing.
 3. A fan assembly, as set forthin 2, wherein the front nozzle is removable.
 4. A fan assembly, as setforth in claim 2, further including an air filter removably locatedwithin the fan housing.
 5. A fan assembly, as set forth in claim 4,wherein the air filter is located near the air inlet.
 6. A fan assembly,as set forth in claim 4, wherein the air filter is within the frontnozzle.
 7. A fan assembly, as set forth in claim 2, the front nozzlebeing adapted to direct air flow out of the open end of the fan housingin a direction generally at a right angle thereto.
 8. A fan assembly, asset forth in claim 1, the fan housing including an electrical junctionbox, the fan assembly further comprising a fan power cord connectedbetween the electrical junction box and the fan.
 9. A fan assembly, asset forth 8, further comprising a hollow rib located on an outer surfaceof the volute portion.
 10. A fan assembly, as set forth in claim 9,wherein the fan power cord is located within the hollow rib.
 11. A fanassembly for use in a computer cabinet, the cabinet having a top paneland at least one side panel connected to the top panel, the top paneland the at least one side panels forming the cabinet, comprising: a fan;a fan housing having a top half and bottom half, the top half and thebottom half forming an internal cavity, an air inlet being located withone of the top and bottom halves, the fan being located within theinternal cavity for directing air from the air inlet towards an open endof the fan housing; and, a front nozzle connected to the fan housing atthe open end of the fan housing.
 12. A fan assembly, as set forth inclaim 11, wherein the front nozzle is detachably connected to the fanhousing.
 13. A fan assembly, as set forth in claim 11, further includinga bottom panel, the bottom panel including at least one aperture andwherein the air inlet of the fan housing is located adjacent the atleast one aperture.
 14. A fan assembly, as set forth in claim 11,wherein the internal cavity has a scroll portion and a volute portion,the volute portion having a narrow portion being connected to the scrollportion and expanding towards the open end of the fan housing.
 15. A fanassembly, as set forth in claim 11, further including an air filterremovably located within housing.
 16. A fan assembly, as set forth inclaim 15, wherein the air filter is located near the air inlet.
 17. Afan assembly, as set forth in claim 15, wherein the air filter is withinthe front nozzle.
 18. A fan assembly, as set forth in claim 11, thefront nozzle being adapted to direct air flow out of the open end of thefan housing in a direction generally at a right angle thereto.
 19. A fanassembly, as set forth in claim 11, the fan housing including anelectrical junction box, the fan assembly further comprising a fan powercord connected between the electrical junction box and the fan.
 20. Afan assembly, as set forth 19, further comprising a hollow rib locatedon an outer surface of the volute portion.
 21. A fan assembly, as setforth in claim 20, wherein the fan power cord is located within thehollow rib.
 22. A computer cabinet, comprising: a frame having a bottomportion and a top portion, the bottom and top portion being connected bya plurality of upright members; a top panel connected to the top portionof the frame; at least one side panel connected to the plurality ofupright members, the top panel and the at least one side panel formingan outer shape of the computer cabinet; a fan housing having a top halfand bottom half and being connected to the frame adjacent an aperture inthe outer shape of the computer cabinet, the top half and the bottomhalf forming an internal cavity, an air inlet being located on one ofthe top and bottom halves, the internal cavity have a scroll portion anda volute portion, the volute portion having a narrow portion beingconnected to the scroll portion and expanding towards the open end ofthe housing; and, a fan located within the internal cavity for directingair from the air inlet towards an open end of the housing.
 23. Acomputer cabinet, as set forth in claim 22, further comprising a frontnozzle connected to the housing at the open end of the housing.
 24. Acomputer cabinet, as set forth in 23, wherein the front nozzle isremovable.
 25. A computer cabinet, as set forth in claim 23, furtherincluding an air filter removably located within the front nozzle.
 26. Acomputer cabinet, as set forth in claim 23, the front nozzle beingadapted to direct air flow out of the open end of the housing in adirection generally at a right angle thereto.
 27. A computer cabinet, asset forth in claim 22, the fan housing including an electrical junctionbox, the fan assembly further comprising a fan power cord connectedbetween the electrical junction box and the fan.
 28. A computer cabinet,as set forth 27, further comprising a hollow rib located on an outersurface of the volute portion.
 29. A fan assembly, as set forth in claim28, wherein the fan power cord is located within the hollow rib.
 30. Acomputer cabinet, comprising: a frame having a bottom portion and a topportion, the bottom and top portion being connected by a plurality ofupright members; a top panel connected to the top portion of the frame;at least one side panel connected to the plurality of upright members,the top panel and the at least one side panel forming an outer shape ofthe computer cabinet; a fan housing having a top half and bottom halfand being connected to the frame adjacent an aperture in the outer shapeof the computer cabinet, the top half and the bottom half forming aninternal cavity, an air inlet being located on one of the top and bottomhalves; a fan located within the internal cavity for directing air fromthe air inlet towards an open end of the housing; and, a front nozzleconnected to the housing at the open end of the housing.